Monolithic slab for roofs, floors, platforms, and the like

ABSTRACT

The means and method herein described may be used to produce upon supporting walls an elevated monolithic slab of concrete or the like, to serve as roofs, gabled or flat, for building structures generally, for floors of buildings, for platforms, etc. Use is made of a simplified form structure comprising a plurality of reusable form units, all alike, assembled side by side and end to end, to be erected upon supporting walls therefor and upon a temporary intermediate supporting means, in such a way as to permit pouring of fluid concrete thereover and thereinto to produce, when set, a slab which rests directly upon the tops of such walls. As part of the monolithic slab thus produced, builtin joists or trusses may be formed upon its underside concurrently in the single concrete-pouring operation involved. All form units are so interfitted as to remain fixedly in operative positions, minus any fastening means therefor, thereby facilitating a subsequent dismantling of the form structure, unit by unit, for removal and repeated use elsewhere.

United States Patent [72] inventor Jack E. Sullivan Fort Laudcrdale, Fla. 21 Appl. No. 818,517 [22] Filed Apr. 23, 1969 [45] Patented Dec. 28, 1971 [73] Assignee Futura Rook, Inc.

Margate, Fla.

Continuation-impart of application Ser. No. 797,937, Feb. 10, 1969, now abandoned. This application Apr. 23, 1969, Ser. No.

[54] MONOLITHIC SLAB FOR ROOFS, FLOORS,

PLATFORMS, AND THE LIKE 5 Claims, 7 Drawing Figs.

"' sim xasmmmmsa Primary Examiner-J. Spencer Overholser Assistant Examiner-John S. Brown Attorney-Ephraim Banning, lll

ABSTRACT: The means and method herein described may be used to produce upon supporting walls an elevated monolithic slab of concrete or the like, to serve as roofs, gabled or flat, for building structures generally, for floors of buildings, for platforms, etc. Use is made of a simplified fonn structure comprising a plurality of reusable fonn units, all alike, assembled side by side and end to end, to be erected upon supporting walls therefor and upon a temporary intermediate supporting means, in such a way as to permit pouring of fluid concrete thereover and thereinto to produce, when set, a slab which rests directly upon the tops of such walls. As part of the monolithic slab thus produced, built-in joists or trusses may be formed upon its underside concurrently in the single concretepouring operation involved. All form units are so interfitted as to remain fixedly in operative positions, minus any fastening means therefor, thereby facilitating a subsequent dismantling of the form structure, unit by unit, for removal and repeated use elsewhere.

Patented Dec. 28, 1971 3,630,479

' ul} 7 m 78 I 111 Ill Hi ATTORNEY MONOLITHIC SLAB FOR ROOFS, FLOORS, PLATFORMS, AND THE LIKE Much of the present invention has heretofore been disclosed in my earlier application filed Feb. 10, I969, Ser. No. 797,937, and now abandoned. The present case is a continuation-in-part of that application.

This invention relates to the production of a slab of concrete or the like concurrently with its formation upon the tops of supporting walls therefor. In practice, such slabs may be advantageously used for roofs, either flat or pitched, and upon buildings of various kinds homes, commercial, etc. The slabs may be produced from some such material as concrete, poured onto and into a form structure erected for its reception at the job, and so carried at or upon the tops of the supporting walls therefor that the slab, when set, will be rested directly and permanently thereon, permitting the form structure to be then freely dismantled for removal and reuse elsewhere, as desired. Means for preventing deflection of the slab, such as joists or trusses extendedintegrally along its under side, may also be formed concurrently in the one and only concrete-pouring operation required, whereby the resulting structure is completely and wholly monolithic throughout.

In the description to follow, application of the invention to the production of building roofs, floors, etc. will first be considered. The slabs therefor may be provided with a plurality of underlying trusses therefor, all integrally united with the slab. The slabs may also be flat on their tops and bottoms, or may be provided on their under sides with supporting joists or trusses integrally united therewith. Slabs of this description may advantageously serve as flat roofs for buildings of many kinds and for floors for buildings, elevated platforms above water or land, etc. In every case production of the slab involves use of a form structure which is carried in large part at or upon the tops of permanent supporting walls, permitting concrete, when poured thereinto, to spread throughout and over the same to produce, when set, a slab which rests directly at or upon the tops of these supporting walls with underlying joists or trusses, if any, extending continuously between such walls which are spaced apart oppositely of each other.

It is one major objective of this invention to provide an allconcrete building slab at a cost which is comparable with, or below, that involved in present day conventional constructions. This is a desideratum highly sought since such a material for roofs, floors, etc., has many advantages, such as low maintenance, low thermal conductivity, and incombustibility. According to this invention, the roof slab may be strengthened by a plurality of trusses (or girders) extending between opposite edges thereof along its under face and with which it is integrally united when produced on the job with the aid of a form structure whose units are few, durable, and simple. For each truss a minimum of four like forms, arranged side by side and end to end, need be used. When set up, their outer ends are rested upon opposite walls of the building. All such forms are also interfitted minus any nails or fasteners, into a rigid and strong load-supporting structure capable of subsequent facile dismantling for reuse elsewhere.

The form units comprised in this invention, although but few in number, suffice for production of self-sustaining trusses capable of spanning widely varying distances between opposite building walls whereon a roof slab is to be supported. Also the supporting framework for the truss forms at spaced points intermediately of the building walls, comprises but few units which may be readily set up and later taken down. All

- such equipment may be conveniently trucked to a building under construction, to be there erected ready for pouring of concrete in an amount sufficient to form, in a single operation, l) all the trusses required for support of the roof, and (2) an overlying slab which is united integrally to all such trusses, when spread evenly over the entire area covered by the form structure provided therefor. Two or 3 days later, with the concrete trusses and roof slab set to a safe point, the units for all such forms and the supporting framework therefore may then be readily dismantled, stacked on one or more flatbed trucks, and delivered back to the yard for temporary storage,

or directly to the site of another building operation where they are again erected and put to use. Trained crews who become experienced in the sequential handling of the units in the form equipment are desirably engaged for each such job which can then proceed smoothly to completion according to a prearranged schedule.

The present improvements reside also in (1) reduction in the number of form units required with a consequent decrease in man hours needed for their erection; (2) adaptability of such units for use on slab jobs which vary widely in size and design; and (3) extension of the form structure beyond the walls of a building to provide for the production of caves thereat, all integral'with the roof slab which spans opposite the building walls to be permanently supported thereby. These,

and other objects of this invention, will appear hereinafter from the ensuing description, taken in conjunction with the accompanying drawings wherein FIGS. 1-7 illustrate various features and advantages of this invention when employed in the production of an all-concrete building roof or floor, in the manner following.

In the drawing, FIGS. 1-7 illustrate the invention as applied specifically to the production of a flat slab for roofs, platforms, etc., which are more or less level, these several figures showing in: 7

FIG. 1 a perspective view of an elongated form unit designed for use with a plurality of other like units in providing a form structure for production of a horizontal slab,-flat on top and bottom, to be carried upon the colevel tops of building walls or uprights which are spaced apart relatively short distances;

FIG. 2 a fragmentary vertical section transversely through two such form units arranged operatively side by side, showing a concrete slab as it appears when freshly poured thereover and before dismantling of the supporting form structure therefor;

FIG. 3 a fragmentary vertical section longitudinally through two such form units arranged operatively end to end, taken on line 33 of FIG. 7, showing a freshly poured concrete slab as it appears when extended thereover and after dismantling of the supporting form structure has started;

FIG. 4 a perspective view of an elongated form unit designed for use with other like form units in providing a form structure for production of a horizontal slab with joists depending monolithically therefrom, to be carried upon the colevel tops of building walls which are spaced apart relatively long distances;

FIG. 5 a view similar to FIG. 2 wherein the form units are rested in part upon horizontal beams of a temporary framework, together with a spread of concrete as it appears when first poured thereover and into fixed spaces between adjacent form units to produce a flat slab with joists depending monolithically therefrom;

FIG. 6 an enlarged fragmentary detail in section, taken on line 66 of FIG. 5, showing the top portions of two spaced walls or uprights supporting the adjacent portions of a freshly poured concrete slab, with the outer end of one form unit resting upon one wall or support, the companion from unit endwise thereof being removed to expose a portion of the joist integrally united thereto, depending therefrom, and resting upon the opposite supporting wall whereon the concrete slab is to be carried; and

FIG. 7 a top plan view of a number of form units according to FIG. I, when assembled operatively into a unitary structure which is rested upon supporting walls therefor and, intermediately thereof, upon a temporary framework.

For simplicity throughout this specification, certain terms have been used with these intended meanings: the supporting walls" whereon the slab is carried in elevated position include any comparable uprights, such as columns, pilings, piers, etc. The term slab" refers to a spread of concrete of the like having a relatively flat top and possibly also a flat underface, adapted to span spaced walls whereon it is carried. Unless otherwise indicated, flat" implies horizontal also, including any pitch sufficient for gravity runoff of water for drainage purposes. Wall tops described as colevel" should be understood to include such as support therebetween a flat slab having a desired pitch to facilitate gravity drainage of water from its top face. With these definitions in mind, this invention in the forms illustrated will now be described in detail.

The flat slab S of FIGS. l3 to be produced from the form units U is adapted to span a pair of relatively closely spaced walls Z. It is also devoid of underlying support when carried on the colevel tops thereof. It may be produced from elongated form units, all alike, each comprising a base or top wall 78 with depending rectangular sidewalls 79 which at one end are interconnected by a cross wall 80. Depending from the bottom of the base wall in its outer end portion is a fulcrum means to elevate the base wall and provide therefor at the top of the supporting wall a pivotal point about which the inner end of the base wall may be swung downwardly. In its zone of juncture with the top wall, the cross wall is provided with a beveled upper section 81 to eliminate any corner thereat. By so doing, the way is cleared for the form units U, during the dismantling stage, to be safely swung downwardly a limited distance (as indicated by the form unit at the left end of FIG. 3), preliminary to complete separation from the slab thereover. A minimum of four such units are arranged with two of them side by side to form a pair and with two such pairs arranged end to end (FIG. 7). Each of these units is supported at its closed end upon the top of a building wall Z, and near its opposite open end upon the jack-supported beam 10 of a temporary supporting framework (FIG. 7) underlying the form units. Between the form units at their meeting ends there need be little or no gap, provided that the form units be of proper length for the span to be bridged. Fiber glass or the like is a material suitable for these form units, and also for those designated as V presently to be described.

The plurality of form units thus carried upon the tops of the walls Z and beams 10 provide in their base or top walls 78 a substantially continuous decking for support of reinforcing rods and/or wires 82 (FIG. 3) to be embedded in the concrete when poured thereon and spread thereover to producethe slab S which then overlies the tops of the walls Z. If desired, supporting brackets for eave forms 47-48 may be affixed to the building walls to receive and support end portions of the slab, adapted to form eaves E for the building.

As shown best in FIG. 3, fasteners at spaced intervals are anchored in the tops of the sidewalls, each in the form of a staple whose two legs 39 are embedded therein. The unconfined looped portion 40 of each staple is then extended horizontally and downwardly to provide an eye 40 which is disposed adjacent the exterior face of the building wall close to or slightly below its top. For each such eye a bracket is provided, comprising an arm 41 connected at one end to a strut 42, the latter at its opposite end being fixedly connected through a leg 43 with the arm 41 at a point near its inner end. A rigid triangular bracket is thereby formed, with the leg and strut at their meeting ends engaging with the outer face of one of the building walls Z. A tongue, formed into a hook 44, projects beyond the inner end of the arm adapted to engage with the eye 40 for support of the bracket upon the wall.

A triangular space remains between the leg and wall, widest at the top, adapted to receive an elongated triangular wedge block 46 whose vertical position is adjustable therein. For a slanting roof, the arm 41 is also free to incline downwardly in conformity with the roof pitch, or otherwise, whereasin an upper position (FIG. 3) the arm may be sustained horizontally to align with the slab of a flat roof. In any selected position, the wedge block is gravity-held against movement due to pressure of the leg thereagainst. An elongated form board 47 having an upstanding flange 48 along one edge is extended along the building wall to receive support therefrom. The width of each form board is such that, when its flanged edge is engaged by retaining fingers 49 upstanding from the arms 41 at their outer ends, the opposite board edge will be rested against the building wall Z near or slightly below its top (FIG. 3). When so supported, the form board may, if desired, be accurately aligned with the top of the completed form structure. Any such or other relationship is assured by properly adjusting the vertical position of the wedge block. Several such form boards, arranged end to end, are positioned along each building wall where eaves are to be provided. In the ensuing pouring operation, the concrete is spread over the roof to a depth substantially the same as elsewhere thereover, whereby each eave becomes an indistinguishable continuation of the roof slab.

Dismantling of the eave forms is a simple operation, requiring first that the wedge block 46 be knocked out, thereby freeing for removal the bracket, and then the form boards. Angle irons may be conveniently be used for the arm, strut, and leg of each bracket.

The slab thus produced with the forms U (FIGS. 1-3) is flat on top and bottom. It rests upon the tops of the walls 2 of the building to provide a continuous roof therefor. No underlying truss or joist need be provided for such a slab, provided that the span therefor be relatively short. But when the building walls are spaced further apart, requiring that joists J or similar strengthening means for the slab be provided, the form unit V of FIGS. 4-5 may be used. Here the vertical dimension of the rectangular sidewalls 83 depending from the base or top wall 84 is substantially increased forgreater resistance to vertical deflections of the base wall. Along the bottoms of the sidewalls out-turned flanges 85 are provided, each having a width of 40 inches or so. Because of the greater vertical dimension of its sidewalls, the cross wall 86 at one end thereof is formed with a beveled section 87 at its point of juncture with the base or top wall 84, and at opposite ends of this beveled section with beveled corners 89, whereby to eliminate any usual corners thereat (FIG. 4). By so doing, the way is cleared for the form units V during the stage of dismantling to be safely swung downwardly a limited distance preliminary to complete separation from the slab thereover. All the form units are alike, made desirably from fiber glass or the like, and assembled to provide two side-by-side pairs which are also arranged end to end. The flanges 85 are then overlapped (FIG. 5) to maintain the proximate sidewalls of adjacent form units spaced apart a fixed minimum distance. The spaces thus provided have double bottoms provided by the overlapped flanges.

When all such form units are in place, pouring of the concrete then follows. While fluid, and spreading over the decking provided by the form unit top walls 84, the concrete is guided into the spaces prepared for reception thereof between proximate sidewalls 83 of the adjacent form units V (FIG. 5). The concrete is then free to spread beyond the closed end of each form unit to rest upon the unoccupied portion of the building top walls Z therebeyond (FIG. 6). When set, and the form structure is dismantled, the slab together with the end portions of the several monolithically formed joists .l on its under face, will be resting directly upon the wall tops to be supported thereby. reinforcing rods and/or wires 88, fixedly positioned on the decking, become embedded in the completed slab and joists to supply reinforcement therefor, as needed.

It will be noted in FIGS. 1 and 2, that the juncture of the sidewalls 79 with the top wall 78 is through a single line of bend approximating 90. Since the slab formed thereover is devoid of any joist or truss depending therefrom, there is no engagement of the concrete with such sidewalls at any point. As a result, separation of the form units from the concrete slab, when set, may proceed with little or no frictional resistance. In FIGS. 4 and 5, however, two lines of bend, each approximating 45 are present in the juncture zone between each sidewall 83 and the top wall 84, and in the slab produced therefrom there is an extended engagement of the concrete with the form structure sidewalls over an area of nearly percent thereof. The frictional resistance to separation of the form units from the solidified slab and depending joists thereof is here much greater. It is found that the provision of adjacent parallel lines of bend in each such juncture zone facilitates bending, if any be needed, whereby to separate the form units from the solidified concrete in the process of dismantling the form'structure, hence the reason or their presence where provision is made for joists or trusses to be formed integrally with the slab.

As is apparent herein, the essential features of this invention are incorporated in each of the several form structures disclosed. In each case all form units used are alike, thereby to minimize their cost and facilitate their use. These units are elongated, as necessary, to approximate half the distance between the building walls whereon the slab-to-be will be carried. As a result, a removable framework erected intermediately of those walls will suffice to support the inner ends of each pair of form units when arranged end to end with their outer ends rested upon proximate portions of the building wall tops, leaving other adjacent portions thereof unoccupied so as to be available for opposite end portions of the slabs-to-be to be rested directly thereupon. The form units, when produced in various lengths and arranged end to end, may then extend between supporting walls which are variously spaced apart, resting always upon the tops of these walls while leaving unoccupied adjacent portions thereof, requisite in size and position, to serve as bases whereon the slabs-to-be may be permanently carried. And to prevent vertical deflection of any slab, when the spanning distance so requires, the present form structure provides for joists or trusses to be formed concurrently in the one and only concrete-pouring operation involved, each such joist or truss depending from the under side of the slab for the length thereof, to be integrally united therewith in a structure which is wholly monolithic.

[claim 1. A form of structure for production of a concrete slab two of whose opposite edge portions are to be rested upon the coplanar tops of spaced supporting walls to be carried thereby comprising a plurality of similar form units all provided with elongated base walls having lengths approximately half the span between the supporting walls, and the fulcrum means depending atone end thereof for elevating each base wall above the tops of the supporting wall therefore, half of the form units being arranged side by side in rows extending transversely of the supporting walls, along with a like number thereof disposed end to end in pairs arranged in parallelism with the supporting walls upon the tops of which the fulcrum means of the form units are adapted to be rested when the inner end of each form unit is rested upon a temporary supporting means located intermediately between the supporting walls, whereby to maintain the base wall of all form units in substantially coplanar relation to provide a decking of substantial area whereon fluid concrete may be spread to form a slab, the resting point of the fulcrum means upon the tops of the supporting walls being located toward their inner faces whereby to leave unoccupied a substantial area therebeyond, the arrangement being such that concrete, when poured in a fluid state over the decking provided by the base walls, will be free to spread beyond the outer ends thereof to rest directly upon the unoccupied portions of the supporting wall tops and, when set to form a solidified slab thereover with the temporary supporting means also removed, permitting downward swinging movement of each form unit upon its fulcrum means around a pivotal point at the top of the supporting wall therefor close to its inner face as an incident to removal of the form unit from between said wall and the concrete slab then resting thereupon and also upon the adjacent supporting wall top.

2. A form structure, as specified in claim 1, wherein the means fixedly joined to each base wall is a pair of vertical sidewalls depending therefrom along opposite edges thereof and interconnected by a cross wall at one end thereof, and wherein relatively narrow flanges are out-turned along the bottom edges of the sidewalls to engage with the sidewalls of adjacent form units to maintain a minimum spacing therebetween when disposed in side-by-side relation, the space thus defined between each two rows of adjacent form units, when assembled into a common structure, bein open at its top and closed by the flanges at its bottom and a so at its ends proximate to the supporting walls therefor, whereby to receive concrete in a fluid state, when poured over the base walls, to produce, when set, a slab thereover having a joist depending therefrom to resist vertical deflection thereof.

3. A form structure, as specified in claim 2, wherein a number of like form units is arranged side by side in parallel rows with the flanges thereof maintaining a uniform'spacin g of their base and vertical walls lengthwise of each row, the spaces.

below the base walls of each pair of form units, when arranged end to end, being continuous between sidewalls thereof and extending to the vertical cross walls at opposite ends of the paired form units, whereby concrete in a fluid state, when spread over the base walls to produce slab thereover, and on to adjacent unoccupied top portions of the supporting walls, will be excluded from entering into each such space.

4. A form structure, as specified in claim 2, wherein the vertical cross walls at their point of juncture with the base walls are contoured to eliminate corners thereat, and wherein the joists to be formed are united integrally with the to-be-formed overlying slab of concrete to provide therewith a monolithic structure which extends beyond opposite ends of the joists to rest directly upon unoccupied portions of the supporting wall tops, the several form units thereafter, upon removal of the intermediate supporting means therefrom, being free at their inner ends to swing downwardly whereby to move their cornerless ends freely through arcuate paths to occupy positions, relative to the overlying concrete slab then resting upon the tops of the supporting walls, from which each form unit may then be separated for removal from the form structure in its entirety.

5. A form structure, as specified in claim 2, wherein the juncture zone between each vertical sidewall and the base wall includes at least two closely spaced parallel bend lines totaling approximately to permit substantially complete interengagement between the concrete, when poured, and percent of the area of one face of each sidewall, when solidified, thereby to facilitate subsequent separation of each form unit from the concrete for dismantling of the form structure. 

1. A form structure for production of a concrete slab two of whose opposite edge portions are to be rested upon the coplanar tops of spaced supporting walls to be carried thereby comprising a plurality of similar form units all provided with elongated base walls having lengths approximately half the span between the supporting walls, and the fulcrum means depending at one end thereof for elevating each base wall above the tops of the supporting wall therefor, half of the form units being arranged side by side in rows extending transversely of the supporting walls, along with a like number thereof disposed end to end in pairs arranged in parallelism with the supporting walls upon the tops of which the fulcrum means of the form units are adapted to be rested when the inner end of each form unit is rested upon a temporary supporting means located intermediately between the supporting walls, whereby to maintain the base walls of all form units in substantially coplanar relation to provide a decking of substantial area whereon fluid concrete may be spread to form a slab, the resting point of the fulcrum means upon the tops of the supporting walls being located toward their inner faces whereby to leave unoccupied a substantial area therebeyond, the arrangement being such that concrete, when poured in a fluid state over the decking provided by the base walls, will be free to spread beyond the outer ends thereof to rest directly upon the unoccupied portions of the supporting wall tops and, when set to form a solidified slab thereover with the temporary supporting means also removed, permitting downward swinging movement of each form unit upon its fulcrum means around a pivotal point at the top of the supporting wall therefor close to its inner face as an incident to removal of the form unit from between said wall and the concrete slab then resting thereupon and also upon the adjacent supporting wall top.
 2. A form structure, as specified in claim 1, wherein the means fixedly joined to each base wall is a pair of vertical sidewalls depending therefrom along opposite edges thereof and interconnected by a cross wall at one end thereof, and wherein relatively narrow flanges are outturned along the bottom edges of the sidewalls to engage with the sidewalls of adjacent form units to maintain a minimum spacing therebetween when disposed in side-by-side relation, the space thus defined between each two rows of adjacent form units, when assembled into a common structure, being open at its top and closed by the flanges at its bottom and also at its ends proximate to the supporting walls therefor, whereby to receive concrete in a fluid state, when poured over the base walls, to produce, when set, a slab thereover having a joist depending therefrom to resist vertical deflection thereof.
 3. A form structure, as specified in claim 2, wherein a number of like form units is arranged side by side in parallel rows with the flanges thereof maintaining a uniform spacing of their base and vertical walls lengthwise of each row, the spaces below the base walls of each pair of form units, when arranged end to end, being Continuous between sidewalls thereof and extending to the vertical cross walls at opposite ends of the paired form units, whereby concrete in a fluid state, when spread over the base walls to produce slab thereover, and on to adjacent unoccupied top portions of the supporting walls, will be excluded from entering into each such space.
 4. A form structure, as specified in claim 2, wherein the vertical cross walls at their point of juncture with the base walls are contoured to eliminate corners thereat, and wherein the joists to be formed are united integrally with the to-be-formed overlying slab of concrete to provide therewith a monolithic structure which extends beyond opposite ends of the joists to rest directly upon unoccupied portions of the supporting wall tops, the several form units thereafter, upon removal of the intermediate supporting means therefrom, being free at their inner ends to swing downwardly whereby to move their cornerless ends freely through arcuate paths to occupy positions, relative to the overlying concrete slab then resting upon the tops of the supporting walls, from which each form unit may then be separated for removal from the form structure in its entirety.
 5. A form structure, as specified in claim 2, wherein the juncture zone between each vertical sidewall and the base wall includes at least two closely spaced parallel bend lines totaling approximately 90* to permit substantially complete interengagement between the concrete, when poured, and 100 percent of the area of one face of each sidewall, when solidified, thereby to facilitate subsequent separation of each form unit from the concrete for dismantling of the form structure. 